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Continuous and rapid manufacturing of ultrathin zeolite membranes with exceptional gas separation performance.

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Title: Continuous and rapid manufacturing of ultrathin zeolite membranes with exceptional gas separation performance.
Authors: Wu, Haolin1 (AUTHOR), Liu, Hongbin1 (AUTHOR), Wang, Bin1 (AUTHOR), Wang, Fan2 (AUTHOR), Ibrahim, Amr F. M.2 (AUTHOR), Yu, Miao2 (AUTHOR) myu9@buffalo.edu, Zhong, Shenglai1 (AUTHOR), Xing, Weihong1,3 (AUTHOR), Zhou, Rongfei1,3 (AUTHOR) rf-zhou@njtech.edu.cn
Source: AIChE Journal. Jun2026, Vol. 72 Issue 6, p1-13. 13p.
Subjects: Membrane separation, Continuous processing, Zeolites, Energy consumption, Mass production, Separation of gases
Abstract: The industrial application of microporous crystalline membranes for gas separation has been persistently hindered by the inefficiency of conventional batch synthesis. To address this limitation, we reported a continuous and ultrafast synthesis (CUS) strategy that enables the efficient production of ultrathin b‐oriented MFI and SSZ‐13 zeolite membranes in just 10–15 min. The resulting MFI and SSZ‐13 membranes exhibited superior separation performance in n‐butane/i‐butane and CO2/N2 mixtures, respectively, far exceeding those of previously reported membranes. Remarkably, the CUS process achieved a two‐order‐of‐magnitude reduction in synthesis time, a 95% decrease in energy consumption and a 98% reduction in gel consumption compared to the batch process. Process simulation using Aspen Plus confirmed that energy consumption was reduced by over 87.6% with membrane separation compared to conventional distillation for butane isomer separation. This work establishes an efficient, scalable, and economically viable pathway for industrial‐scale fabrication of zeolite membranes for gas separation. [ABSTRACT FROM AUTHOR]
Copyright of AIChE Journal is the property of Wiley-Blackwell and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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Header DbId: egs
DbLabel: Engineering Source
An: 193398358
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
PreciseRelevancyScore: 0
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  Data: Continuous and rapid manufacturing of ultrathin zeolite membranes with exceptional gas separation performance.
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  Data: <searchLink fieldCode="AR" term="%22Wu%2C+Haolin%22">Wu, Haolin</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Liu%2C+Hongbin%22">Liu, Hongbin</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wang%2C+Bin%22">Wang, Bin</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wang%2C+Fan%22">Wang, Fan</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Ibrahim%2C+Amr+F%2E+M%2E%22">Ibrahim, Amr F. M.</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Yu%2C+Miao%22">Yu, Miao</searchLink><relatesTo>2</relatesTo> (AUTHOR)<i> myu9@buffalo.edu</i><br /><searchLink fieldCode="AR" term="%22Zhong%2C+Shenglai%22">Zhong, Shenglai</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Xing%2C+Weihong%22">Xing, Weihong</searchLink><relatesTo>1,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zhou%2C+Rongfei%22">Zhou, Rongfei</searchLink><relatesTo>1,3</relatesTo> (AUTHOR)<i> rf-zhou@njtech.edu.cn</i>
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  Data: <searchLink fieldCode="JN" term="%22AIChE+Journal%22">AIChE Journal</searchLink>. Jun2026, Vol. 72 Issue 6, p1-13. 13p.
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  Data: <searchLink fieldCode="DE" term="%22Membrane+separation%22">Membrane separation</searchLink><br /><searchLink fieldCode="DE" term="%22Continuous+processing%22">Continuous processing</searchLink><br /><searchLink fieldCode="DE" term="%22Zeolites%22">Zeolites</searchLink><br /><searchLink fieldCode="DE" term="%22Energy+consumption%22">Energy consumption</searchLink><br /><searchLink fieldCode="DE" term="%22Mass+production%22">Mass production</searchLink><br /><searchLink fieldCode="DE" term="%22Separation+of+gases%22">Separation of gases</searchLink>
– Name: Abstract
  Label: Abstract
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  Data: The industrial application of microporous crystalline membranes for gas separation has been persistently hindered by the inefficiency of conventional batch synthesis. To address this limitation, we reported a continuous and ultrafast synthesis (CUS) strategy that enables the efficient production of ultrathin b‐oriented MFI and SSZ‐13 zeolite membranes in just 10–15 min. The resulting MFI and SSZ‐13 membranes exhibited superior separation performance in n‐butane/i‐butane and CO2/N2 mixtures, respectively, far exceeding those of previously reported membranes. Remarkably, the CUS process achieved a two‐order‐of‐magnitude reduction in synthesis time, a 95% decrease in energy consumption and a 98% reduction in gel consumption compared to the batch process. Process simulation using Aspen Plus confirmed that energy consumption was reduced by over 87.6% with membrane separation compared to conventional distillation for butane isomer separation. This work establishes an efficient, scalable, and economically viable pathway for industrial‐scale fabrication of zeolite membranes for gas separation. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of AIChE Journal is the property of Wiley-Blackwell and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1002/aic.70321
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      – Code: eng
        Text: English
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        PageCount: 13
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    Subjects:
      – SubjectFull: Membrane separation
        Type: general
      – SubjectFull: Continuous processing
        Type: general
      – SubjectFull: Zeolites
        Type: general
      – SubjectFull: Energy consumption
        Type: general
      – SubjectFull: Mass production
        Type: general
      – SubjectFull: Separation of gases
        Type: general
    Titles:
      – TitleFull: Continuous and rapid manufacturing of ultrathin zeolite membranes with exceptional gas separation performance.
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            NameFull: Wu, Haolin
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            NameFull: Liu, Hongbin
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            NameFull: Ibrahim, Amr F. M.
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            NameFull: Yu, Miao
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            – D: 01
              M: 06
              Text: Jun2026
              Type: published
              Y: 2026
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